PCD Round Tools for High-Efficiency Aluminum Machining

Kennametal Inc. (Pittsburgh, PA) is leveraging its experience with PCD tooling for the automotive industry to provide a line of round tools for manufacturers seeking a cost-competitive solution for aluminum machining. Drills, reamers and end mills made from PCD grade KD1410, particularly effective with the high-silicon-content aluminum used to make engine blocks and cylinder heads, are up to 10 times more productive than carbide tooling. They provide exceptional tool life and wear resistance even in very abrasive aluminum alloys and are available with very short lead times.

In drilling and reaming operations, the tools perform at cutting speeds of up to 900 m/min (3,000 SFM). Milling operations can be performed at 6 m/min (20,000 SFM).

With through-the-tool coolant capabilities and an MQL-ready interface, the tools are ideal for both rough and finish machining. Extremely sharp cutting edges and low-friction rake surfaces eliminate concerns over built-up edge.

Low-friction machining also produces superior surfaces in finishing operations such as reaming. Surface roughness of Ra 0.1- to 0.8-micron, far superior to conventional carbide tooling, is achievable.

The PCD end mills feature 6-to-50-mm diameters; cutting depths up to 50 mm; various rake angles; and center cutting, roughing and finishing geometries.

The PCD drills feature 6-to-20-mm diameters in 0.5-mm increments up to 5xD in inch and metric sizes.

The PCD reaming portfolio features 6-to-20-mm diameters in 1-mm increments; through and blind hole versions; modular system with KST coupling available for diameters up to 42 mm.

Many can be requested as custom solutions with short lead times.

www.kennametal.com